Fused bath electrolytic cell



p i 1963 G. "r. MoTocK FUSED BATH ELECTROLYTIC CELL Fi led Aug. 16. 1960 9 Sheets-Sheet 1 INVENTOR. GEORGE T. MOTOCK ATTORN Y5 FIG.4

A ril 16, 1963 G. T. MOTOCK 3,085,967

FUSED BATH ELECTROLYTIC CELL Filed Aug. 16, 1960 Q-Sheets-Shet 2 F G. 2 INVENTbR.

GEORGE T. MOTOCK lZwww w ATTORN YS April 16, 1963 G. T. MOTOCK 3, 8

FUSED BATH ELECTROLYTIC CELL Filed Aug 16, 1960 9 Sheets-Sheet 3 'INVENTOR. GEORGE T. MQTOCK BY W i zwul') ATTORNE S April 16, 1963 e. T. MOTOCK 3,085,967

FUSED BATH ELECTROLYTIC CELL Filed Aug. 16, 1960 9 Sheets-Sheet 4 FIG. l2

INVENTOR. GEORGE T. MOTOCK ATTORNEY April 16, 1963 G. 'r. MOTOCK FUSED BATH ELECTROLYTIC CELL 9 Sheets-Sheet 5 Filed Aug. 16, 1960 FIG.|4

FIG. l5

INVENTOR. GEORGE T. MOTOCK BY (M Ztaaul" M4;

ATTORNEYS April 16, 1963 Filed Aug. 16, 1960 G. T. MOTOCK FUSED BATH ELECTROLYTIC CELL 9 Sheets-Sheet 6 VLN'VENTOR.

eEoRe'EWmo'rocK ATTOR Y5 April 16, 1963 G. T. MOTQCK 3,085,967

FUSED BATH ELECTROLYTIC CELL Filed Aug. 16, 1960 9 Sheets-Sheet 7 INVEN TOR. GEORGE T. MOTOCK ATTORNEYS April 16, 1963 G. T. MOTOCK 3,085,967

FUSED BATH ELECTROLYTIC CELL Filed Aug. 16, 1960 9 Sheets-Sheet 8 FIG.23

INVENTOR.

204 GEORGE T. MOTOCK QMMJ" ATTORNEY April 16, 1963 G. T. MOTOCK 3,085,967

FUSED BATH ELECTROLYTIC CELL Filed Aug. 16, 1960 9 Sheets-Sheet 9 FIG.25

FIG.26

INVENTOR.

GEORGE T. MOTOCK ATTORNEYS .anode without destruction of the cell floor.

United States Patent G This invention relates to improvements in the design of cells used for the production of alkali metals, e.g., sodium and lithium, by electrolysis of a fused salt. In particular, this invention relates to a novel anode and novel sealing and electrical connection means for anodes for such fused salt cells.

In the operation of fused salt cells, a fused salt mixture is electrolyzed to produce alkali metal at the cathode and halogen gas at the anode. The anode is conventionally a cylindrical graphite or carbon anode surrounded by an annular metallic cathode. A porous diaphragm is pro vided in the anode-cathode annular space to assist in the separation of the products of electrolysis.

The fused salt electrolyte bath is very corrosive, par.- ticularly a fused mixture of lithium chloride and potassium chloride used to produce lithium, and due to the high temperature of operation, serious problems of leakage of the molten electrolyte are present, particularly around the anode when it is a bottom entrant type. Leakage of electrolyte through the bottom entrance of the anode results in costly shut-downs of cell operation and rebuilding of the cell floor. Also, with conventional graphite anodes, chlorine flow and ion distribution are somewhat hindered by the small cathode-anode annular space.

This invention provides a novel graphite anode which has the advantages of decreased resistance to chlorine flow in the anode compartment of the cell, increased ion distribution in the cathode-anode annular space and low voltage drop across anode to cathode. The novel anode is a cylindrical, solid, graphite anode having a plurality of slots along its greater axis. In particular, the anode is substantially vertical and has a plurality of substantially vertical slots in the area surrounded by the cathode. As contrasted to a hollow anode with slots extending into the hollow interior, the larger amount of graphite present in the slotted, solid anode of this invention not only gives a reduction in current density at the operating amperage level and, therefore, permits the size of the active zone to be decreased, but also reduces the operating voltage. The life and mechanical strength of the anode is increased because of the large amount of graphite present. Also, the overall voltage increase as the anode life decreases is proportionally less. Also, the cost of machining the anode is decreased.

This invention also provides a novel and effective means for sealing a bottom entrant anode to prevent escape of molten electrolyte around such anode and at the same time provide for easy removal and replacement of the The scaling is accomplished by providing a metal enclosure or receptacle attached to and extending below the cell bottom, through which a cylindrical, vertical, graphite anode extends. The anode is of reduced diameter near the enclosure opening to form a shoulder which rests on electrical insulating support means inside the enclosure. The portion of reduced diameter is sealed in the enclosure opening by a sealing ring between the insulating support -means and enclosure bottom and a packing gland exterior to the enclosure bottom. The anode is sealed in the cell bottom and enclosure by refractory insulating means.

This invention also provides a novel and effective connector for supplying electrical energy to the external por- 3,085,957 Patented Apr. 16., 1963 tion of a bottom entrant cylindrical anode which provides good electrical contact during cell operation. The connector comprises two opposed metal sections each having a semi-cylindrical interior surface for fitting around the external portion of the cylindrical anode, means for holding the sections together and tightly against the anode surface, means in each section for conducting a coolant therethrough and means on each section for connection to a source of electrical energy. The coolant reduces the temperature in the lower anode portion and assists in sealing by freezing any moltenelectrolyte leaking around the anode. Also, the coolant aids in reducing expansion of the metal parts preventing loosening of the connection.

The invention will be further illustrated by reference to the accompanying drawings which illustrate a fused salt electrolysis cell with four anodes and cathodes and designed for operation at 30,000 amperes and for the production of lithium from a mixture of lithium chloride and potassium chloride.

FIGURE 1 is a plan view of the fused salt electrolysis cell with the cover removed.

FIGURE 2 is a view of the section taken along 22 of FIGURE 1.

FIGURE 3 is a side view of one of the anodes of FIGURE 1.

FIGURE 4 is a cross-sectional view of the anode sealing means of FIGURE 1.

FIGURE 5 is a plan view of the anode connector of FIGURE 1.

FIGURE 6 is a front view of the anode connector of FIGURE 1.

FIGURE 7 is an end view of the anode connector of FIGURE 1.

FIGURE 8 is a cross-sectional view taken through 8-3 of FIGURE 5 showing a typical water-cooled area.

FIGURE 9 is a plan view of the cathode assembly of FIGURE 1, showing the anodes and diaphragms in place.

FIGURE 10 is a front elevation view of the cathode assembly of FIGURE 9.

FIGURE 11 is a side elevation View of the cathode assembly of FIGURE 9.

FIGURE 12 is a detail of the dam of FIGURE 9.

FIGURE 13 is a plan view of the assembly of FIGURE 1 for collecting the products of electrolysis.

FIGURE 14 is a sectional view taken through 1414 of FIGURE 13.

FIGURE 15 is a sectional view taken through 1515 of FIGURE 13.

FIGURE 16 is a cross-sectional view of a pilot post of FIGURE 1.

FIGURE 17 is a plan view of the chlorine dome of FIGURE 1.

FIGURE 18 is a cross-sectional view taken through 18-18 of FIGURE 17.

FIGURE 19 is a plan view of the lithium metal riser and overflow pipe assembly of FIGURE 1.

FIGURE 20 is a cross-sectional view taken through 2020 of FIGURE 19.

FIGURE 21 is a cross-sectional view taken through 2121 of FIGURE 20.

FIGURE 22 is a cross-sectional view taken through 22-22 of FIGURE 20.

FIGURE 23 is a plan view of the holding tank of FIG- URE 1.

FIGURE 24 is a cross-sectional view taken through 2-424 of FIGURE 23.

FIGURE 25 is a plan view of the valve seat of the holding tank of FIGURES 23 and 24.

FIGURE 26 is a cross-sectional and front elevation view of the valve seat taken along 26-26 of FIGURE 25.

FIGURE 27 is a partial bottom view of the valve seat of FIGURE 25 In the drawings, and as shown generally in FIGURES 1 and 2, the basic cell structure 100 is formed from metal and refractory material and the cell contains four bottom entrant cylindrical anodes 200, for which anodes sealing means 300 are provided,'as Well as anode connectors 400 for supply of electrical energy. The anodes are surrounded by an assembly of four cathodes 500 with opposed side arms. A porous diaphragm 600 is positioned between each cathode and anode. A collecting assembly 700 for collecting chlorine and lithium metal products is positioned above the cathode-anode area and is supported by a collector assembly support 800 and positioned and aligned by pilot posts 900. Chlorine is recovered by means of dome 1000 and lithium metal by means of riser 1100 and holding tank 1200.

The cell 100, as shown particularly in FIGURES 1 and 2, is formed from an outer cylindrical shell of steel 101 lined with refractory material 102, e.g., extruded acid proof brick or power pressed brick. The bottom of the cell is formed from a circular steel table 103 lined with refractory material, e.g., brick 104, insulated from the ground by four porcelain insulators 105. The table 103 extends beyond the outer shell 101 and a metal dam 106 is placed on the outside rim of the cell bottom. This is filled and rammed with castable refractory material 107 sloping upwards to the cell shell to a height above the bottom of the cell. This forms a seal with the flange 108 on the bottom of the cell to prevent molten electrolyte leakage. Also, high density monolithic castable refractory cement material 109 is used over the refractory brick to form the bottom lining or floor of the cell. Vertical steel supports 110 and horizontal beams 111 are provided to support the cell bottom. The top of the cell is formed from steel plate 111 lined with refractory material, e.g., brick 102.

The anodes 200 are cylindrical, solid, graphite anodes and contain, as shown particularly in FIGURE 3, spaced slots 201 in the area adjacent the cathode. As shown in FIGURE 9, the slots do not extend through to the center of the anode. Preferably, the slots extend to only about one-third of the diameter of the anode. The anodes of this particular cell are sixteen inches in diameter with twenty-four slots, each slot being one-eighth inch wide and two inches deep. Also, an anode with twelve slots, each slot being one-quarter inch wide and two inches deep can be used. The twelve slot anode is faster and easier to machine. Each anode is machined from dense graphite with an overall length of sixty-eight inches. The slots extend twenty-three inches downward from the top of the anode. The slotted, solid anode provides decreased resistance to chlorine flow in the anode compartment of the cell, increased ion distribution in the cathode-anode annular space and low voltage drop across anode to cathode.

The anode is provided with a portion of reduced diameter 202 at the lower end thereof forming a shoulder 203 to facilitate supporting and sealing the anode, electrically and mechanically. In the particular cell illustrated, the lower twenty inches of the anode is reduced to a ten inch diameter.

The supporting and sealing means 300 for the anodes, as shown particularly in FIGURE 4, comprises the shoulder 203 of the anode 200 which rests on an insulating ring 301 inside a squared metal, e.g., steel, enclosure, e.g., a box or pan-like section 302 attached to the cell bottom 103. The ring 301 serves to insulate electrically the pan from the anode. The box is concentrically located be- I neath a circular steel cell bottom. The box is divided into four quadrants each containing an opening for the anode. The portion of the anode of reduced diameter 202 passes through the opening in the box section 302 and the opening is sealed by means of a metal sealing ring 303 between the insulating ring 301 and the pan bottom 304 and a packing gland 305. The gland 305 is adapted to hold packing 306 tightly against the anode and sealing ring 303 by means of bolts 307 engaging the gland, cell bottom and sealing ring. The anode is sealed in the cell bottom and box by means of refractory material 308, e.g., refractory brick. In the cell illustrated, the insulating ring 301 serving as electrical insulation between the anode and steel shell is a three-quarter inch thick transite ring with an outside diameter equal to that of the upper anode portion and an inside diameter slightly larger than the lower anode portion. Special quadrant refractory 308 brick, four inches thick, are laid as fill for the anode box to seal the anode in the box. They are laid three high with refractory cement as a filter. The cell floor 108 of castable refractory material is laid to a depth of two inches over the quadrant brick. After drying, the cell and packing gland are tightened to complete the anode seal. The sealing means effectively prevents escape of molten electrolyte around the anode and at the same time provides for easy removal and replacement of the anode without destruction of the cell floor.

Electrical energy is supplied to the anodes by means of anode connectors or clamps 400, as shown particularly in FIGURES 5 to 8. The clamp comprises two opposed metal sections 401 each having a semi-cylindrical interior surface 402 for fitting around the external portion of the cylindrical anode, bolts 403 for holding the sections 401 together and the interior surfaces tightly against the anode surface, passages 404 with pipe connectors (bushings) 405 within each section for the flow of coolant through the sections and studs 406 for connection to buses. The cooling of the clamp cools the lower portion of the anode and also freezes any molten electrolyte that may leak around the anode seal. Also, the coolant aids in reducing expansion of the metal parts preventing loosening of the connection. A copper bus is attached to each half of the clamp by means of the four studs 406 and a four sided frame which bolts the bus tightly to the clamp. The clamp is preferably made from silicon bronze rather than mold steel because of the compatibility of silicon bronze and copper bus connections and also because of its high resistance to corrosion as well as high strength. The sections 401 can be machined from solid stock or cast and partially machined. The portions of the clamp facing the graphite anode (surfaces 402) and copper bus (surface 407) are plated with silver to insure good electrical contact. In the particular clamp illustrated, the clamp, when tightened, forms a ten inch diameter by ten inch high sleeve and faces 1130.4 inches of graphite giving a current density of 26.54 amperes per square inch at 30,000 amperes.

The cathode assembly 500 includes cylindrical steel cathode sleeves or rings 501 concentrically surrounding each anode and having opposed steel side arms 502. As shown particularly in FIGURES 1 and 2 and 9 to 12, the side arms 502 of the illustrated cell support the group of four cathode cylinders 501. The walls of the cathode cylinders are solid. In the particular cell illustrated, the inner diameter of the cathode ring is nineteen inches. The anode-cathode spacing is one and onehalf inches. The side arms 502 rest on the refractory brick lining of the cell wall and extend through the outer shell of the cell and are machined and silvered to accommodate a copper bus which is clamped to the arm in a manner similar to the anode by means of studs 503. The side arms are provided with passages 504 for flow of coolant. The side arms are insulated and sealed against electrolyte leakage by means of a metal, e.g., steel, enclosure or box 505 mounted on the side of the cell shell through which box the side arms pass (see FIGURES 1 and 2). The box comprises four walls 506 attached to the cell shell 101 and a side plate 507 bolted to the walls 506. A metal dam or dike 508 is welded to the side arm 502 so that the dam 508 is approximately centrally located with the box 505. After the brick shell is built around the cathode arms, castable refractory ccment 509 is rammed and packed into the box so that it is in tight contact with the cell and box walls and side arms and the dam thereon. The castable refractory material and dam effectively prevent the molten electrolyte from leaking through the cathode seal. The dam also can be in the shape of a U. Also, an additional dam can be attached to the inside of the box to provide a more tortuous path for the electrolyte and prevent its leakage. Also, the coolant in the cathode side arm serves to freeze any molten electrolyte leaking into the box and thus aids the seal. The side plate 507 has an opening 5 through which the cathode arm passes without contacting the plate. The opening is designed to leave a gap around the cathode side arm to insure against electrical contact between the arm and the metal shell of the cell. Thus, the cathode side arm is in contact only with refractory material which serves as insulation.

The diaphragms 600 are cylindrical sleeves positioned in the area between each anode Q00 and cathode sleeve 501. The preferred diaphragm, as shown in detail in FIGURE 14, is a preforated metal sheet, although other types made from porous ceramic materials, e.g., alumina, magnesia or other oxides non-reactive with the electrolysis products, or metal wire screens can be used. The metal sheet can be carbon steelor stainless steel of at least twenty-four gauge thickness. The important feature of the diaphragm is the percentage of open area. The open area required varies with the electrolysis conditions, i.e., the composition, temperature and viscosity of the molten salt mixture (electrolyte) employed. An open area of about 30 to 50 percent has been found to be satisfactory for the illustrated cell. In the particular cell illustrated, the preferred diaphragm is a cylinder of twenty-four gauge perforated stainless steel (type 304 or 316) sheet of an inner diameter of seventeen inches and an overall length of twenty-four and one-quarter inches. The perforations are 0.038 inch in diameter, 0.05 on centers both ways giving 400 openings per square inch or 45.5 percent open area straight-line pattern. In another example, the openings are 0.038" diameter, 0.05" 0.057 center with 351 openings per square inch or 39 percent open area. The dimensions of a 26 gauge, 306 grade stainless steel used are 0.30 inch diameter openings, about 22.5 holes per square inch or 36 percent open area. The actual shape of the openings is not important. A 0.020 inch thick sheet with slits 0.016 inch wide by 0.140 inch long can be used as a diaphragm. The stainless steel diaphragm is better than one made of carbon steel because carbon steel requires a thicker gauge for strength and rigidity similar to that of stainless steel. A wire diaphragm of carbon steel is unsatisfactory due to buckling in operation. The diaphragm is suspended from the chlorine and metal collecting assembly 700 by means of machined metal adapter ring 601 fitting inside the upper end of the diaphragm and welded thereto. The ring '601 has a portion of reduced diameter 602, projecting above the diaphragm and is bolted to the collecting assembly. This structure is very advantageous in that it reduces the size of the collecting assembly and thus the overall size of the cell. Also, a strengthening ring of metal 603 is attached to the bottom of the diaphragm.

The collecting assembly 700 comprises essentially a hoodwith an inclined upper surface and having within the skirts of the hood cylinders for holding a diaphragm between an anode and cathode and for guiding anode products to a cone-shaped structure on the inclined surface having an opening in its top for gas discharge, while cathode products are guided by the hood skirt enclosure to a discharge opening in the highest part of the inclined surface. As shown in detail in FIGURES 13 to 15, the preferred collecting assembly comprises a single steel unit of a large centrally located cylinder 7 01 (which can be squared on one section as shown) designed to collect the chlorine evolved at the anode side of the diaphragm 600- and the liquid metal formed at the cathode side of the diaphragm. Four smaller cylinders 7021 extend downward from the large central cylinder 701 and hold the ,diaphragms 600, by means of adapter ring 601, so that passages for chlorine from all the anodes are provided. The chlorine evolved on the anode side of the diaphragm passes up through the smaller cylinders 702' and 'into a cone-shaped structure 703 on top of the large cylinder which provides an upwardly sloping smooth surface to a small cylinder or pipe 704, preferably of stainless steel, forming an opening through which the chlorine passes to the chlorine dome 1000. Advantageously, a metal screen or baffle 709 can be placed over the chlorine outlet 704 and a calming effect is obtained which reduces salt entrainment. The cone-shaped structure on one side advantageously extends down into the smaller cylinders 702 as shown as 705 to form an upwardly sloping smooth surface for chlorine flow and to eliminate gas pockets. The upper surface of the large cylinder 701 has an inclined surface, preferably about 10 from horizontal, so as to form an inverted inclined trough 70-6 encircling the small cylinders 702 and the anode-cathode area and lithium metal formed at the cathode side of the diaphragm flows up from the cathodes to the trough and out through lithium metal outlet 707. As shown in FIGURE 2, the collecting structure 700 is preferably completely submerged in the molten electrolyte or melt, with the outlet pipe 704 positioned just below the melt line. The melt line in the chlorine dome 1000 is higher than in the cell proper because the pressure in the dome is less than that in the cell proper. The pipe 704 is kept below the melt line to minimize corrosion and erosion from the hot chlorine gas. By the use of suitable materials, however, the pipe can project above the melt line. The collecting structure effectively separates chlorine and lithium in the electrolyte and guides them to structures for their recovery. The collecting structure prevents their re-combination which would result in contaminated lithium and effectively prevents entrainment of electrolyte in the chlorine stream. The assembly is provided with posts 708, preferably of stainless steel, threaded to receive hangers for suspension from the collecting assembly support 800. While the preferred hood structure is substantially cylindrical, a substantially rectangular or square hood, preferably rounded on the corners to correspond to the smaller downwardly projecting cylinders can be used. 7

The collector support 800, as shown particularly in FIGURE 1, comprises a diamond shaped steel structure,

positioned on top of the cell, with arms 801 and cross pieces 802 and 804. The collector assembly is suspended from the support by means of the cross pieces 804 attached to the arms 8011 with bolted hanger rods 805 which thread into the collector posts 708. Each end of the diamond shaped structure formed by arms 1 is supported by attachment to a pilot post 900.

The steel pilot posts 900 are attached to steel frame work 111 and (which also supports the cell proper) and serve through the collector support 800 to position and align the collector assembly 700, including diaphragms 600, and chlorine dome 1000. The post 900, as shown particularly in FIGURE 16, comprises a bot- .tom casing 901 containing a pilot shaft 902 With pilot shaft guide sleeves 903 for receiving set screws 904- for holding and positioning horizontally the pilot shaft'902. The pilot shaft 902 is insulated from the bottom casing by transite ring 905 and is provided with an insulating transite cover 906- on which rests plate 907 which receives adjusting screw 900 in adjusting collar 909 of the FIGURES 17 and 18, for recovering chlorine after it is separated from the electrolyte comprises a cylindrical (e.g., about two feet diameter) shell 1001, preferably of stainless steel, lined with refractory brick 1002 and castable refractory 1003. At the top of the dome is a centrally located pipe 1004 (e.g., about eight inch diameter) providing an opening for escape of chlorine gas. A metal cone 1005 is provided for supporting the refractory brick and castable refractory. The refractory lining provides effective protection against the corrosive hot chlorine gas and any entrained melt. Flanges 1006 are provided for engagement with cross pieces 802 of the collector support structure 800. The pipe 1004 is in a steel cover plate 1007 which also contains an opening 1008 sealed by gaskets for pressure relief and an opening 1009 sealed by a glass plate for visual observation of operation. Preferably, the dome is insulated on its exterior to prevent plugging from freezing of any molten electrolyte. The dome 1000 is supported from (and positioned by) the collector assembly support 800 by means and cross pieces 802 engaging the flanges 1006 (see FIGURES l and 2). As shown in FIGURE 2, the dome 1000 is slightly raised (e.g., one and one-half inches) above the collector 700 so that it does not rest on it in order to provide for circulation of electrolyte. As shown, the dome is positioned over the pipe 704 of the collector 700 and has its lower portion submerged in the melt. The pipe 704 of the collector projects up into the shell 1001, but, as discussed above, the pipe 704 should not project above the melt surface to avoid corrosion and erosion. Chlorine is passed from the dome opening 1004 into a recovery system by means of piping 1010. The cylindrical refractory-lined dome effectively separates the chlorine in high purity of 99 percent or more with substantially no entrainment of electrolyte and has a long operating life even under the very severe conditions. It provides a low, uniform gas velocity which substantially eliminates entrainment.

The lithium metal riser 1100, as shown in detail in FIGURES 19 to 22, functions to move the lithium metal which is collected in the annular spacing (inverted inclined trough) under the collector 700, by virtue of the difference in specific gravity between the liquid lithium and the molten eutectic salt mixture, to the hold tank 1200. The riser comprises a cylinder 1101, preferably of stainless steel, with a top plate 1102 and containing in its lower portion and adapted to fit snugly over the pipe opening 707 for lithium metal flow from the collector 700, a smaller interior cylinder 1103, preferably of stainless steel, located off-center and adjacent to one portion of the cylinder 1101 so as to provide a semi-annular space 1104 so that lithium metal flows up through the cylinder 1103 and into the space 1104. The smaller interior cylinder 1103 extends up into the cylinder 1101 a distance suflicient to bring its top at least to the melt line and preferably at the melt line. The riser is supported by the pipes 1105 and 11% attached to hold tank 1200 and cylinder 1101 (see FIGURE 2). Hold tank 1200 can be positioned vertically or horizontally to align the cylinders 1101 and 1103 over the collector opening 707 and with respect to the melt level.

The lithium metal flows from the space 1104 and cylinder 1101 up through an inverted V-shaped pipe structure, preferably of stainless steel, comprising an upwardly inclined (e.g., 45) pipe 1105 extending into the cylinder 1101 and over the edge of interior cylinder 1103. The metal flows up the pipe 1105 and then down a downwardly inclined (e.g., 60 from vertical) pipe 1106 into a holding tank 1200. At the top of the inverted V intersection of the two pipes 1105 and 1106 a blind flange 1107 is provided, which can .be removed to unplug the pipes 1105 and 1106 through opening 1108, in the event they become plugged with frozen electrolyte or metal. Maintaining pipe 1105 and 1106' at a temperature of the lithium metal from contact with air.

about 300 C. by external heating helps to prevent plugging. The top plate 1102 can contain opening 1109 and pipe 1106 opening 1110 for piping any chlorine gas evolved directly to the chlorine header 1010 to prevent recombination of chlorine and lithium and recover the chlorine. The riser can then be operated successfully without an argon pad, although argon padding can be provided if desired through opening 1111. Argon padding is used to prevent nitridation and oxidation of When chlorine is piped directly to the chlorine header 1010 the suction on the header must be carefully controlled so as to prevent metal carryover into the gas line.

The riser effects a complete separation of lithium of high purity, i.e., 99 percent or more. Recombination of lithium and chlorine is virtually eliminated, as well as entrainment of electrolyte. After long service, the riser is exceptionally clean and free from salt or metal accumulation.

The holding tank 1200, as shown in detail in FIG- URES 23 and 24, is designed to accumulate and hold lithium metal during a cell campaign. It comprises a cylindrical tank 1201, preferably of stainless steel, with a top plate 1202 having an opening for inflow of lithium metal by pipe 1106 from the riser 1100. The bottom 1203 of the tank is inclined downwardly from the lithium inlet side to an opening 1204 in the opposite side for discharge of lithium metal which is controlled by a valve 1205, controlled by means of stem 1206 from the top of the tank. Opening 1207 is provided for argon padding to prevent nitridation and oxidation of the lithium. The tank is heated by means of external heaters, particularly along the tank bottom, to maintain the molten lithium at temperatures at least about 50 C. higher than the melting point of lithium (186 C.), e.g., about 250 C. The temperature must be maintained evenly over the entire area of the tank or else the lithium metal freezes, particularly in the area around the seat of valve 1205. A jacketed valve seat 1208, as shown in detail in FIGURES 25 to 27, equipped with heaters, e.g., cartridge heaters, effectively prevents such failures from freezing of lithium. The seat 1208 is provided with holes 1209 for receiving the cartridge heaters and between the heaters holes 1210 for thermocouples for controlling the cartridge heaters are provided.

In the operation of the illustrated cell, a mixture of lithium chloride and potassium chloride was charged to the cell to form the melt. The mixture was first subjected to a pre-electrolysis period, preferably with alternating current, to form the molten electrolyte. The preelectrolysis not only removes water of hydration from the salt but also removes the chemically bound impurities, i.e., metal hydrides and hydroxides which cannot be removed by heating alone. Following this period, the electrolyzing current. is applied. The composition of the molten electrolyte was maintained at about 40 to 50 percent lithium chloride. The electrolyte temperature was maintained at about 400 to 480 0, preferably about 420 to 460 C., at a current level of about 20,000 to 30,000 amperes. The temperature can be maintained without the addition of external heat. Operating conditions for optimum production are a current level of 24,000 to 26,000 amperes, an electrolyte composition of 46 to 48 percent lithium chloride, an electrolyte temperature of 450 C., and an electrolyte level of about 2 to 4 inches from the top rim of the cell. Maximum current efficiency is obtained at 25,000 amperes, at which level gives an anode current density of 6.55 and a cathode current density of 5.51 amperes per square inch. Operating at current levels below 24,000 or above 26,000 amperes results in reduction in current efiiciency. High melt concentration causes a marked reduction in the cathode to diaphragm potential with excessive formation of surface metal. Deviation from an electrolyte temperature of 450 C. results in reduction in current efficiency. An increased amount of corrosion occurs on the cathode when the melt level falls below 4 inches.

On electrolysis of the fused salt mixture, chlorine was formed at the anode and directed by the diaphragm to the collector assembly and separated from the electrolyte in the refractory-lined chlorine dome. The lithium formed at the cathode on the cathode side of the diaphragm collected in the inverted inclined trough and flowed into the metal riser where it was separated from the electrolyte and flowed to the holding tank, which was periodically drained.

The chlorine from the chlorine dome was of high purity, i.e., above 99.0 percent, and the lithium metal from the hold tank was of a purity of about 99.5 percent, in contrast to prior lithium cells wherein for lack of adequate separating structures chlorine was not recovered and lithium was removed from the bath surface as a crude product containing lithium and potassium chloride impurities.

What is claimed is:

1. In a fused salt electrolysis cell including a cylindrical anode entrant through the cell bottom and cathode means surrounding the anode, the combination of means defining an enclosure attached to and extending below the cell bottom, a cylindrical vertical solid graphite anode extending through an opening in the bottom of the enclosure and having a plurality of spaced slots along its greater axis in the area adjacent the cathode, said slots extending only partially into the anode, the anode being of reduced diameter near the enclosure opening forming a shoulder above the enclosure opening which rests on electrically insulating support means inside the enclosure, said anode portion of reduced diameter being sealed mechanically in the enclosure opening by means comprising a metal sealing ring between the insulating support means and enclosure bottom and a packing gland exterior to the enclosure bottom engaging the sealing ring, said anode being sealed in the cell bottom and enclosure by refractory insulating means, and connecting means for supplying electrical energy to the external portion of the anode comprising two opposed solid, metal sections each having a smooth, continuous, semi-cylindrical interior surface for fitting around the cylindrical anode, means for holding said sections together and the interior surfaces tightly against the anode surface, coolant passages in each of said sections for conducting a coolant through the sections and electrical conducting means on each section for connection to a source of electrical energy.

2. The connecting means of claim 1 in which the sections are of silicon-bronze metal and the interior surfaces are plated with silver.

3. The combination of claim 1 in which the slots in the anode extend to only about one-third of the diameter of the anode.

References Cited in the file of this patent UNITED STATES PATENTS OTHER REFERENCES Wol-dman: Engineering Alloys (1954), page Serial No. 13,522. 

1. IN A FUSED SALT ELECTROLYSIS CELL INCLUDING A CYLINDRICAL ANODE ENTRANT THROUGH THE CELL BOTTOM AND CATHODE MEANS SURROUNDING THE ANODE, THE COMBINATION OF MEANS DEFINING AN ENCLOSURE ATTACHED TO AND EXTENDING BELOW THE CELL BOTTOM, A CYLINDRICAL VERTICAL SOLID GRAPHITE ANODE EXTENDING THROUGH OPENING IN THE BOTTOM OF THE ENCLOSURE AND HAVING A PLURALITY OF SPACED SLOTS ALONG ITS GREATER AXIS IN THE AREA ADJACENT THE CATHODE, SAID SLOTS EXTENDING ONLY PARTIALLY INTO THE ANODE, THE ANODE BEING OF REDUCED DIAMETER NEAR THE ENCLOSURE OPENING FORMING A SHOULDER ABOVE THE ENCLOSURE OPENING WHICH RESTS ON ELECTRICALLY INSULATING SUPPORT MEANS INSIDE THE ENCLOSURE, SAID ANODE PORTION OF REDUCED DIAMETER BEING SEALED MECHANICALLY IN THE ENCLOSURE OPENING BY MEANS COMPRISING A METAL SEALING RING BETWEEN THE INSULATING SUPPORT MEANS AND ENCLOSURE BOTTOM AND A SPACING GLAND EXTERIOR TO THE ENCLOSURE BOTTOM ENGAGING THE SEALING RING, SAID ANODE BEING SEALED IN THE CELL BOTTOM AND ENCLOSURE BY REFRACTORY INDULATING MEANS, AND CONNECTING MEANS FOR SUPPLYING ELECTRICAL ENERGY TO THE EXTERNAL PORTION OF THE ANODE COMPRISING TWO OPPOSED SOLID, METAL SECTIONS EACH HAVING A SMOOTH, CONTINUOUS, SEMI-CYLINDRICAL INTERIOR SURFACE FOR FITTING AROUND THE CYLINDRICAL ANODE, MEANS FOR HOLDING SAID SECTIONS TOGETHER AND THE INTERIOR SURFACES TIGHTLY AGAINST THE ANODE SURFACE, COOLANT PASSAGES IN EACH OF SAID SECTIONS FOR CONDUCTING A COOLANT THROUGH THE SECTIONS AND ELECTRICAL CONDUCTING MEANS ON EACH SECTION FOR CONNECTION TO A SOURCE OF ELECTRICAL ENERGY. 